Process for spreading or dividing textile materials



Dec. 19, 1957 3,358,436

PROCESS FOR SPREADING 0R DIVIDIVENG TEXTILE MATERIALS GENTARO NHNA ETAL2 Sheets-Sheet 1 Filed Oct. 19, 1964 GENTARO NmvA,

- Yosurvuxz SAsAKI, Ann 7 INVENTOR :BY

Dec. 19, 1967 GENTARO NllNA ETAL 3,358,435

PROCESS FOR SPREADING OR DIVIDING TEXTILE MATERIALS Filed Oct. 19, 19642 Sheets-Sheet 2 N NASAYUKI TAR s11:

INVENTORS ,w BY

' ATTORNEYS United States Patent 3,358,436 PROCESS FOR SPREADING ORDIVIDING TEXTILE MATERIALS Gentaro Niina, Yoshiynki Sasaki, and MasayukiTakahashi, Iwakuni-shi, Yamaguchi-ken, Japan, assignors to TeijinLimited, Osaka, Japan Filed Oct. 19, 1964, Ser. No. 404,602 Claimspriority, application Japan, Nov. 5, 1963, 39/ 17,789 9 Claims. (Cl.57-162) ABSTRACT OF THE DISCLOSURE A substantially non-twisted strand ofcontinuous textile filaments is spread electrically into individualfilaments by imparting electrical conductivity to the filaments, forexample by spraying water thereon, and then introducing a high electricpotential of at least 5000 volts to the wet filaments. The water appliedto the filaments may contain surface active agents and/or electrolytes.The process afiords extremely stable operability and high productivity,and is applicable for example to the production of intimately blendedcontinuous filament yarn from two or more different multifilament yarns.

The present invention relates to a process for spreading or dividingone-dimensional, textile materials consisting of a number of continuousfilaments such as yarns, strands, tows and the like into individualfilaments. The previous method for spreading or dividing continuousmultifilament yarns into individual monofilaments or a plurality thereofwas generally carried out by electrically charging said continuousmultifilaments by friction and utilizing repulsive power generatedbetween monofilaments. However, this method had the disadvantage thatonly hydrophobic fibers which were easy to charge by friction could behandled by said method, and that even when fibers of good chargeabilitywere used, amounts of charge were extremely unstable depending on themoisture content of fibers, oily agents attached thereto and humidityconditions, thus providing a low effect in spreading or dividingfilaments.

In addition to the above method, there was another which utilizedradiations in charging. This method was also defective in that amountsof charge widely fluctuated depending on the moisture content of fiberscharged, oily agents attached thereto and conditions of atmospherichumidity, thus requiring radiations of considerably high intensity.

One of the primary objects of the present invention is to eliminate theaforementioned difiiculties encountered in the previous methods andprovide a new process for spreading or dividing one-dimensional textilematerials consisting of continuous multifilaments such as yarn, strands,tows and the like into individual monofilaments. Another object of thepresent invention is to provide a spreading process which has a highdividing effect, uniformly spreads yarns into monofilaments equallyspaced from each other and, moreover, is capable of stable operation. Aspecific object of the present invention is to provide a process foreffectively spreading even those filamentary textile materials (forexample, rayon) to which the previous charge dividing method could notbe applied. Further objects and advantages of the present invention willbe clear from the following description.

The aforesaid objects and advantages can be achieved by the process ofthe present invention which comprises imparting electric conductivity toone-dimensional textile materials consisting of continuousmultifilaments, applying to them a high voltage current to an extent ofat least 3,358,436 Patented Dec. 19, 1967 ice 5000 volts, therebyspreading said materials into individual monofilaments.

Illustrative embodiments of the invention will now be described withreference to the accompanying drawings, in which:

FIGURE 1 is a schematic diagram of an apparatus for carrying out thespreading process of the invention;

FIGURE 2 is a perspective view of a device for un twisting twistedfilaments;

FIGURE 3 is an enlarged cutaway view of a device for imparting electricconductivity to the filaments;

FIGURES 4a and 4b are perspective views of alternative forms ofelectrodes used in the separating or dividing of the filaments;

FIGURES Sal to 5e2 are respective perspective and sectional views ofditferent configurations of blended y FIGURE 6 is a schematic diagram ofan apparatus for carrying out the process of the invention when used toblend filaments; and

FIGURE 7 is a schematic diagram of an apparatus for carrying out theprocess of the invention when used to produce covered yarns.

In this specification, one-dimensional textile materials consisting of anumber of continuous filaments may be referred to as multifilamentarytextile materials or continuous multifilaments.

As seen in FIG. 1, continuous multifilaments are introduced from bobbin1 through compensator 6 controlling filament tension into means 2 forimparting electric conductivity to said filaments. Then continuousmultifilaments are subjected to the process of the present invention ina non-twisted form or a state approximating it (namely, a statecomprising not more than about 5 twists per meter). The feed device forcontinuous multifilaments should be of such type which provides no morethan 5 twists of said filaments per meter. In other words, in thepresent invention, a means for directly feeding filaments can be usedwhen they are not substantially twisted. Also in case filaments aretwisted, a device (such as shown in FIG. 2) is employed to feed saidfilaments while untwisting them. a

The continuous multifilaments leaving bobbin 1 are given electricconductivity in means 2. Electric conductivity may be imparted byspraying filaments to be treated with water or aqueous solutions ofsurface active agents (for example, anionics such as high alcoholsulfuric ester salts, aliphatic amine salts and alkyl phosphoric esters,cationics such as the quaternary ammonium and pyridium salts,amphoterics such as high aliphatic amino alcohol sulfuric ester andphosphoric ester and nonionics such as polyoxyethylene alkyl ether andpolyoxyethylene polyoxypropylene alkyl ether) and aqueous solutions ofinorganic electrolytes (for example, LiCl, NaSO, and MgCl) or byimmersing said multifilaments in these electric conductivity agents orby padding the multifilaments with said agents. Continuousmultifilaments may undergo treatments for electric conductivity beforebeing taken up by bobbin 1. When the continuous multifilaments alreadycontain large amounts of anti-static agents (surface active agents) itwill be suificient to expose said filaments to atmospheres of highhumidity. The extent to which electric conductivity should be imparteddepends on the kind, denier and tension of the filaments to be treatedand the degree of required spreading. However, it is desirable in Withfilaments having a higher resistance than 5X10 Sl/cm./d., it isimpossible to obtain a desirable spreading effect. Again with filamentshaving a lower resistance than 2X10 Q/cm./d., filaments are likely to bedamaged, although spreading may be accomplished to a desired extent.FIG. 3 shows details of means 2 for imparting electric conductivity byspraying. Compressed air is jetted from nozzle 23 through duct 22. Atthis time the jetted air blows electric conductivity agents 24 on tofilaments 21 in their atomized form. The electric conductivity agents 24are introduced through line 25, so that their level can be keptconstant. The amounts of agents imparting electric conductivity to thefilaments to be treated can be controlled by adjusting the pressure ofair supplied through line 22, as long as the shape of nozzle 23, thedistance between nozzle 23 and filaments 21 and the level of electricconductivity agents 24 charged remain unchanged. This air pressure isreferred to as spraying pressure. The term may sometimes be used toexpress the amounts of electric conductivity agents applied on arelative basis.

The continuous multifilaments to which electric conductivity has beenimparted are conducted through feed rolls 7, depending on circumstances,to electrode 4 coupled to a high voltage power source 3. For the processof the present invention, any high voltage power source may be used, ifit supplies filaments with at least 5000 volts of electric current. Thecurrent may be alternating, but preferably is direct. Although the upperlimit for the voltage applied is not critical, a voltage up to about100,000 v. is suitable from the practical standpoint of insulationtechniques. Suitable electrodes for use in the process of the presentinvention are such types as shown in FIGS. 4a and 4b in addition to thatshown in FIG. 1.

The continuous multifilaments through which electric current has thusbeen introduced are divided due to repulsive power between individualmonofilaments and are spread over spread rolls 5 which are substantiallygrounded. The potential of electrode 4 may be positive or negative. Whenthe potential of electrode 4 is positive the electric current flowsthrough the filaments and spread rolls, starting with electrode 4, andruns also from electrode 4 through the filaments and means 2 forimparting electric conductivity.

According to the process of the present invention, it is possible tocarry out spreading as required, regardless of the kind of filaments tobe treated. With the previous charge spreading method, it waspractically impossible to conduct the spreading of hydrophilic filamentssuch as rayon. However, with the process of the present invention, thespreading of even rayon can be carried out effectively. Furthermore, theprocess of the present invention is not relatively sensitive to themoisture content of the filaments to be treated, amounts of oily agentsattached thereto and the degree of humidity in which the operation isperformed, and therefore is capable of stable operation. The extent ofspreading can also be varied over a wide range by controlling thevoltage used.

The spreading process of the present invention is applicable in thebroad field of the fiber manufacturing industry. For example, saidspreading process can be utilized in the manufacture of blendedcontinuous filament yarns consisting of more than two differentcontinuous monofilaments which have been divided and then mixed well.

Hitherto, a large number of chemical fibers and synthetic fibers havebeen developed and used in combination with natural fibers in manydifferent fields in accordance with their respective properties.However, these properties did not always meet the requirements of thosefields in which they were applied. Therefore to meet said requirements,composite properties were imparted to yarns or fabrics by mixing thesefibrous strands or by means of mixed weaving or spinning.

For a uniform composition of different kinds of staple fibers, it ispossible to blend more than two different monostaples and spin saidblended staple fibers into yarns. However, such a process is notpracticable in the composition of different kinds of continuousfilaments. Mixed stianding may be used as a means for composingdifferent kinds of filaments into yarns. However, according to thisstranding process, mixed strand yarns consist of separate strands ofmore than two different kinds of multifilament yarns. In other words,they represent nothing but aggregates of individual different kinds ofsaid filaments. (FIG. 5a.) Consequently these yarns have such propertiesas described below. Although they have strong points in their way, yetthey also have shortcomings in another sense. (1) The yarns consistingof filaments thus stranded become grandville yarns depending ondiiferences in the dyeability and luster of individual component yarns,but are incapable of producing sprinkled color effects. (2) Toillustrate the properties of the yarns under review, their apparentoverall life is restricted almost solely by the life of one of thecomponent filaments which has relatively lower quality, andinterfilament compensation is not satisfactorily attained. Consequentlythe features of higher quality filaments are diflicult to display. (3)The relative positions of individual component filaments are maintainedonly by twisting and are easily alfected by the number of twists usedand also readily get out of shape. (4) It is difficult to obtainvarieties embodying the composite properties of individual componentfilaments, for example, bulky yarns in which the ditferent contractionrates of the component filaments are utilized;

The foregoing shortcomings can be eliminated by attaining such a blendedstate as in blended spun yarns. The desired blended continuous filamentyarns can be manufactured by a process according to the presentinvention,

for example, as illustrated in FIG. 6, by spreading difierent kinds ofcontinuous multifilaments separately and placing types (A) and (B) ofsaid filaments thus spread one on top of the other in such a manner thatthey can be blended most easily and taking up the mixture by drawtwister 3. The blended continuous filament yarns obtained are shown inFIG. 5b and are in striking contrast to the mixed strand yarns in FIG.5a.

Also for various purposes, for instance, to restrict extensibility,facilitate handling or improve touch, the so called core yarns have beendeveloped which consist of filament yarns provided with a covering.According'to the previous method, said core yarns are prepared bywinding covering yarns directly around the core yarn, with the resultanttrouble that the wrap is too thick. (FIG. 5c.) Obviously, when extremelyfine covering yarns are used in this case, thin layers of wrapping areobtained. However, this makes covering yarns quite expensive andoperation difiicult from the standpoint of strength. Moreover, since theprocessing speed substantially drops, the operation is extremelyinefiicient and impractical. However, as previiously described, theprocess of the present invention en.- ables multifilaments to be dividedinto individual monofilaments. Therefore, if said multifilaments areused as a covering in a spread state as shown in FIG. 7 even the use ofthick covering material can produce substantially the same efiect as iffine covering material was used. The covering yarns thus obtained areshown in FIG. 5e.

The process of the present invention is also applicable in theprocessing of crimped yarns. In the previous known methods of crimpingincluding stuffing and false twisting filamentary crimped yarnsconsisting of two different filaments were obtained either by jointlytwisting said two yarns which had been separately crimped in advance orby crimping said two yarns after they had been jointly twisted. Ineither case the trouble was that no crimped yarns could be obtainedwhich consisted of two difierent yarns whose monofilaments werecompletely blended, and that two layers of spotty patterns wereobserved. According to the process of the present invention, however,yarns consisting of two diiferent yarns whose monofilaments arecompletely blended can be crimped. Consequently crimped yarns thusobtained present no spotty phases. Again in the edge crimping method,one of the crimping processes, filaments which were positioned in thecentral part of the multifilament did not come in contact with the bladeedge,

so that fully crimped yarns were not obtained. For this reason onlymonofilaments were usually used in the edge crimping method. However,according to the process of the present invention individualmonofilaments are separated from each other as illustrated in FIGS. 1and 6 and can be brought in contact with the edge, thus enablingmultifilaments to be fully crimped.

6. EXAMPLE 2 Nylon 6 yarns consisting of 110 d.-30 filaments were spreadin the same manner as was used in Example 1. Table 2 below shows thespread widths (cm.) obtained on spread rolls 5 at indicated spraypressures (kg/cmF), filament resistances (SZ/cmj d. as measured at30,000 v.)

and indicated DC. power (v.).

The process of the present invention will be more clearly understod withreference to the examples which follow. However, it should be noted thatthe present invention is not limited to those examples.

EXAMPLE 1 Non-twisted polyethylene terephthalate yarns consisting of 75d.-36 filaments were spread on spread rolls 5 providing a maximum spreadwidth of cm., using the same equipment as shown in FIG. 1 excepting thatelectrode 4 illustrated in FIG. 4a was used. In this case the feed speedfor treatment of filaments was 300 m./mi n. and the feed tension was 0.1g./d. Electric conductivity was imparted by spraying water, using ameans shown in FIG. 3. Table 1 below shows the spread widths (cm.)obtained on spread rolls 5 at indicated spray pressures (kg./cm.filament resistances obtained by spraying (Q/CIIL/d. as measured at30,000 volts) and indicated D.C. power (v.).

Next the filaments which had been spread at a spray pressure of 0.20kg./crn. and DC. power of 25,000 were wound up in contact with the edgewhile heated to 120 C., at a feed speed of rn./min., and initial tensionof 2 g./d., with the contact angle between the edge and the filimentsset at 7. The filaments thus obtained were crimped very uniformly andeffectively. The capacity of said filaments to be crirnped was more thantwice that of non-divided filaments.

EXAMPLE 3 Rayon yarns of d.-75 filaments were spread in the same manneras was followed in Example 1. Table 3 presents the spread widths (cm.)obtained on spread rolls TABLE 3 Spray pressure (Resistance) Voltage v.

0.00 0.10 0.15 0.20 0.25 0.30 (8X10 (1.2X10 (6.0Xl0 (7.1X10 (2.3Xl0)TABLE 1 Spray pressure (Resistance) Voltage v.

0.00 0.15 0.20 0.25 0.30 (3X10 (1.6X10 (2.7X10) (2.0X10 (1.8X10

Cm. 0971.. Cm. 01nd 0161. 016:. 10, 000 0 0 5 15, 000 0 0 6 14 3 0 20,000 0 0 5 14 15 13 25, 000 0 0 5 14 15 15 30, 000 0 0 4 13 15 15 35, 0000 0 6 12 15 15 40, 000 0 0 5 13 15 15 Next the filaments which had beenspread at a spray pressure of 0.25 kg./cm. and DC. power of 20,000 v.were grouped into sets each consisting of four filaments. They werefurther subdivided and taken up on a winder. Sub-division according tothis example enabled much higher productivity and stability than thatwhich was possible with the previous method based on friction charge.

Next the filaments which had been spread at a spray pressure of 0.25kg./cm. and DC. power of 35,000 v. were wound up on a draw twister withthe process shown in FIG. 7, while being covered with polyethyleneterephthalate yarns of 30 d.12 filaments by inserting them betweenspread rolls 5.

The textile thus obtained by the use of said covering yarns wasuniformly colored without sprinkled patterns and its tensile strength tothe same textiles of EXAMPLE 4 With an apparatus illustrated in FIG. 6,non-twisted polyethylene terephthalate yarns of 75 d.36 filaments andnon-twisted rayon yarns of 75 d.34 filaments were separately spread withDC. power of 35,000 v. Both yarns were placed one on the other on spreadrolls 5 with their widths adjusted to the same extent and then wound upwhile being twisted. In this case a means 2 in the part handling thepolyethylene terephthalate yarns was arranged so as to apply a 2%aqueous solution of dodecyl alcohol sulfuric ester sodium salt to thefilaments through a spongy medium. The electric resistance of saidfilaments Was set at 2.5 10 Q/cm/d, as measured at 30,000 v. On theother hand, a water-spraying apparatus was used in the part handlingrayon yarns. The electric resistance of said filaments was controlled to6X10 Q/cm/d. as measured at 30,000 v. The width of the electrode 4 wasset at 12 cm. Then treatment was conducted at a feed rate of 400 m./min.and a feed tension of 0.1 g./d. for both filaments.

The textile fabricated from yarns thus obtained which consisted ofblended monofilaments presented no moi-re phenomenon which had beenobserved in the traditional mixed strand fabric and had better surfaceendurance.

EXAMPLE 5 With an apparatus shown in FIG. 6 except for bobbin 1 andelectric conductivity means 2, acetate yarns of 50 d.l4 filaments and 20twist/m. and nylon 66 yarns of 100 d.48 filaments and 20 twist/m. wererespectively spread and then blended at a feed rate of 300 m./min. and afeed tension of 0.5 g./d. with 20,000 v, pulsating current introducedthrough electrode 4 at 60 c./s. Bobbins 1 used then respectivelyconsisted of such apparatus as illustrated in FIG. 2, so that the yarnscould be untwisted nearly completely. The acetate filaments were treatedwith saturated steam so that they could be given electric conductivitywith their resistance averaging 5x10 Q/cmJd. as measured at 30,000 v.The nylon 66 filaments were also given electric conductivity by beingdipped in a bath containing a 0.5% aqueous solution of polyoxyethylenenonylphenol ether (B) with their resistance averaging 3x10 Sz/cmJd. asmeasured at 30,000 v.

Next the filaments which had been blended in a spread state wereintroduced into a twist apparatus shown in the United States Patent No.2,803,109 to obtain crimped yarns. Said yarns had no portions wheredifferent types of filaments were separateddue to varying degrees ofcrimping between them. Thus the blended yarns showed nearly the sameuniform appearance as that observed in the crimped yarns consisting ofthe same kinds of filaments.

EXAMPLE 6 With the same appartus as shown in FIG. 6 except for electricconductivity means 2, non-twisted nylon 6 yarns of 1680 d.272 filamentsand non-twisted acetate yarns of 1200 d.l20 filaments were spread onspread rolls allowing a maximum spread width of 20 cm. at a feed rate of100 m./min. and a feed tension of 0.5 g./d. and thereafter blended bybeing placed one on the other, The DC. power used had a voltage of100,000 v.

The electric conductivity means 2 consisted for the nylon 6 yarns of abath provided with pad rolls which contained a 0.8% aqueous solution ofpolyoxyethylene octyl ether (EO) and for the acetate yarns of a bath inwhich to dip said yarns in an aqueous solution of 0.5 of Na SO and LiCl.

Next the filaments which had been blended in a spread form wereintroduced into an apparatus as illustrated in the United States PatentNo. 2,854,728 (Japanese patent publication: No. Sho 27-4048) beforebeing wound up to obtain crimped yarns. An economical'carpet having asoft handling was manufactured from said crimped yarns.

EXAMPLE ,7

With an apparatus shown in FIG. 1, non-twisted polyvinyl chloride yarnsof d.24 filaments which had only been elongated and not heat treatedafter spinning were spread at a feed rate of 200 m./min The filamentsthus spread were given electric conductivity by spraying water with ameans shown in FIG. 3 to such extent that they had a resistance of 3X10Q/cmJd. The DC. power introduced into electrode 5 had a voltage of 5000v.

Next the yarns still remaining in a spread state were partially heattreated with a high frequency heater before they were wound up. Themonofilaments of said yarns were heat treated under exactly the sameconditions. Consequently When the yarns were woven into fabric, followedby finishing, a soft bulky fabric of high uniformity was obtained.

Having described the specifications, we claim:

1. Process for spreading one-dimensional solid textile materials eachconsisting of a number of continuous filaments, which comprisesimparting electric conductivity to said material by applying anelectrically conductive liquid thereto, and then applying thereto anelectric current of at least 5000 volts, thereby spreading the materialsinto individual filaments.

2. Process as claimed in claim 1 in which said onedimensional textilematerials are yarns or tows.

3. Process as claimed in claim 1 which is characterized by impartingelectric conductivity to said one-dimensional textile materials to theextent that their resistance is not higher than 5 X 10 Sz/cm/d. asmeasured at 30,000 volts.

4. Process as claimed in claim 1 in which electric current is applied tosaid one-dimensional materials when they are in their substantiallynon-twisted state.

5. Process for spreading one-dimensional solid textile materialsconsisting of a number of continuous filaments which are substantiallyuntwisted comprising applying an electrically conductive liquid theretoto impart to said textile materials electric conductivity to the extentthat their resistance ranges between 2 X 10 to 5 X 10 Q/cm/d. asmeasured at 30,000 volts and thereafter spreading and dividing saidmaterials into individual filaments by applying thereto an electriccurrent of 5000 to 100,000 volts.

6. Process for preparing intimately blended continuous solid filamentyarns from at least two different multifilament yarns, which comprisesapplying electrically conductive liquid to the solid filaments of eachof the two different yarns for imparting electric conductivity to eachof said two different solid multi-filament yarns applying an electriccurrent of at least 5000 volts to each of said yarns in theirsubstantially non-twisted state to spread each of said yarns intoindividual filaments and thereafter winding up said two yarns togetherinto a single yarn in which all said individual monofilaments areintimately blended.

7. Process as claimed in claim 6 in which the step of imparting electricconductivity to said different multifilament yarns comprises makingtheir respective resistances no higher than 5x10 fl/cmJd. as measured at30,000 volts.

8. Process as claimed in claim 6 in which the step of imparting electricconductivity to each of said multifilament yarns comprises making theirrespective resistance in a range from 2x10 to 5X 10 Q/cm/d. as measuredat 30,000 volts, and the step of applying an electric current comprisesapplying from 5000 to 100,000 volts to each of said yarns in theirsubstantially non-twisted form.

9. A process for preparin a textile yarn in which a core yarn is coveredwith a plurality of filaments, comprising spreading a multifilarnentyarn having a plurality of solid filaments into individual spacedfilaments by applying to the filaments an electrically conducting liquidand then applying thereto an electric current of at least 9 5000 volts,feeding a textile core yarn onto said spread 2,953,893 multifilamentyarn, and twisting the thus superposed yarns 3,046,632 into a singlecovered yarn. 3,070,950 3,268,971 References Cited 5 UNITED STATESPATENTS 2,158,415 5/1939 Formhals 28-1 2,825,199 3/1958 Hicks 57-36 10Smith et a1. 57 157 X Tsutsumi 28-1 Thomas 57-157 Lockwood 28--1 FRANKJ. COHEN, Primary Examiner.

JOHN PETRAKES, Examiner.

1. PROCESS FOR SPREADING ONE-DIMENSIONAL SOLID TEXTILE MATERIALS EACHCONSISTING OF A NUMBER OF CONTINUOUS FILAMENTS, WHICH COMPRISESIMPARTING ELECTRIC CONDUCITIVITY TO SAID MATERIAL BY APPLYING ANELECTRICALLY CONDUCTIVE LIQUID THERETO, AND THEN APPLYING THERETO ANELECTRIC CURRENT OF AT LEAST 5000 VOLTS, THEREBY SPREADING THE MATERIALSINTO INDIVIDUAL FILAMENTS.